Diesel Data: Automotive Repair
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Engine Assembly

Fig. 10 Assembling piston to connecting rod:





PISTON & CONNECTING ROD

1. Assemble piston to rod as shown in Fig. 10.
2. Install piston pin retaining clip into one end of piston groove, then press pin in until it contacts clip.
3. Install remaining clip into piston groove.

PISTON RINGS

1. Install oil ring expander and rails into oil ring groove.
2. Install second, then the top compression ring. When installing compression rings, make sure markings on rings face upward.



Fig. 11 Positioning ring end gaps:





3. Position ring end gaps as shown in Fig. 11.

INSTALLING CRANKSHAFT

1. Clean contact surfaces of cylinder block, main bearings and crankshaft.
2. Install the five sets of main bearings to the cylinder block and bearing caps.
3. Coat crankshaft journals and main bearings with fresh engine oil. Only coat the outer surface of bearing with engine oil. The bearing cap side of the main bearings should be kept dry.
4. Gently place crankshaft into cylinder block.
5. Install thrust washers onto No. 3 main bearing cap, making sure oil grooves face outward.
6. Install main bearing caps, making sure arrows on caps are facing towards front of engine.
7. Torque main bearing caps to specifications.
8. Coat rear oil seal outer lip with engine oil, then install oil seal and retaining bolts.

INSTALLING PISTON & CONNECTING ROD ASSEMBLY

1. Lubricate entire assembly with fresh engine oil.



Fig. 10 Assembling piston to connecting rod:





2. Compress rings using suitable ring compressor, then install piston and rod assembly into cylinder block by tapping piston head with a wooden drift. Install piston by positioning as shown, Fig. 10.
3. Install connecting rod bearing halves into their respective locations in rods and bearing caps.
4. Lubricate outer surface of bearings and the crankshaft journals with fresh engine oil, then install connecting rod bearing caps to connecting rod, making sure weight marks on cap and rod align.
5. Torque bearing caps to specification.
6. Turn crankshaft to make sure rotation is smooth and no binding exists.

INSTALLING CAMSHAFT

1. Coat camshaft journals and lobes with fresh engine oil.
2. Carefully slide camshaft into cylinder block.
3. Install thrust plate and thrust plate retaining bolts. Torque bolts to 15 ft.lbs.

INSTALLING OIL PUMP & STRAINER

1. Position oil pump into cylinder block.
2. Install oil pipe onto pump cover and cylinder block using new gaskets, then tighten retaining bolts.
3. Install oil pump setscrew and locknut at side of cylinder block.

TIMING CASE, GEARS & COVER

1. Install timing case to cylinder block, then torque retaining bolts to 15 ft.lbs.



Fig. 12 Aligning timing gear marks:





2. Install crankshaft timing gear onto crankshaft, making sure keyway aligns with key, then install washers and oil slinger. When installing timing gears, align timing marks on gears as shown in Fig. 12.
3. Install camshaft gear, washers and lock bolt onto camshaft, then torque lock bolt to 48 ft.lbs.
4. Install injection pump drive gear.
5. Install idler gear spindles, then the idler gears, thrust plates, lock washers and retaining nuts. Torque retaining nuts to 20 ft.lbs.
6. Install timing cover using a new gasket, then torque retaining bolts to 15 ft.lbs.

OIL PAN, FLYWHEEL & CLUTCH

1. Install new oil pan gasket set, applying suitable sealer to cylinder block, timing case and contact area of gasket.
2. Install oil pan, then the oil pan attaching bolts. Torque attaching bolts to 7 ft.lbs.
3. Install end plate and torque end plate retaining bolts to 29 ft.lbs.
4. Install flywheel to crankshaft, then torque retaining bolts to 95-137 ft.lbs.
5. Install clutch assembly.

CRANKSHAFT PULLEY

1. Install flywheel brake 49 E301 060 or equivalent, onto flywheel ring gear.
2. Install pulley, washer and retaining bolt, then torque retaining bolt to 145-181 ft.lbs. When installing crankshaft pulley, make sure keyway in pulley aligns with crankshaft key.

CYLINDER HEAD & ROCKER ASSEMBLY

1. Lubricate and install tappets into their respective bores.
2. Position new cylinder head gasket onto cylinder block, then install cylinder head, making sure dowels are correctly aligned.
3. Lubricate and install pushrods, valve caps and the rocker assembly.



Fig. 2 Cylinder head bolt tightening sequence:





4. Install rocker shaft and cylinder head bolts, then torque bolts to 80-85 ft.lbs., in sequence shown in Fig. 2.

INTAKE MANIFOLD

1. Install intake manifold to cylinder head using a new gasket.
2. Torque intake manifold retaining bolts to 12-17 ft.lbs.

INJECTION PUMP

1. Position injection pump into timing case, making sure key on pump shaft aligns with keyway in drive gear.
2. Install injection pump to case attaching bolts and nuts.
3. Install drive gear lock plate, spring washer and locknut. Torque locknut to 29-51 ft.lbs.
4. Install drive gear cover and cover retaining nuts.
5. Install injectors and glow plugs into cylinder head. Torque injectors to 43-51 ft.lbs. and glow plugs to 7-11 ft.lbs.
6. Connect injection pipes to injectors and torque flare nuts to 18-22 ft.lbs.
7. Connect fuel hoses and fuel cut solenoid coupler.

FINAL ASSEMBLY

1. Install water pump.
2. Install thermostat housing.
3. Install fan and pulley.
4. Install alternator.
5. Connect vacuum sensing tube.
6. Install starter.

PURGING AIR FROM FUEL SYSTEM

Whenever the injection pump has been removed, the fuel system should be bled as follows:


Fig. 13 Fuel filter priming pump and air vent location:





1. Loosen the fuel filter air vent plug, then press the priming pump up and down until a steady flow of fuel flows from vent plug, Fig. 13. Close the vent plug while keeping priming pump depressed.



Fig. 14 Injection pump head bolt location:





2. Loosen the injection pump head bolt, Fig. 14, then crank engine until fuel flows from head bolt. Torque head bolt to 12 ft.lbs.
3. Disconnect injection pipes at injectors, then crank engine until fuel flows from injection pipes. Reconnect injection pipes and torque to 18-22 ft.lbs.

ADJUSTING VALVE CLEARANCE

1. Start engine and allow it to reach normal operating temperature.



Fig. 2 Cylinder head bolt tightening sequence:





2. Loosen cylinder head bolts in reverse order of sequence shown in Fig. 2.
3. Torque cylinder head bolts to specification in sequence, Fig. 2.
4. Position No. 1 cylinder at TDC of compression stroke, then adjust the following valves to specification: Intake valves 1, 2; Exhaust valves 1, 3.
5. Rotate the crankshaft 360°, then adjust the following valves to specification: Intake valves 3, 4; Exhaust valves 2, 4.
6. Install valve cover and torque retaining bolts to 2-3 ft.lbs.

INJECTION PUMP TIMING

To check injection pump timing, proceed as follows:
1. Disconnect injection pipes from injection pump.



Fig. 14 Injection pump head bolt location:




Fig. 15 Aligning timing mark with pointer:





2. Remove head bolt from injection pump, Fig. 14, then align timing mark (2° ATDC) with pointer as shown, Fig. 15.



Fig. 16 Injection pump plunger measuring tool:





3. Mount measuring tool 49 9140 076 or equivalent, into head bolt hole, making sure that tip of dial indicator pointer contacts the plunger end of the pump, Fig. 16. Dial gauge should indicate approximately .080 inch.



Fig. 17 Changing crankshaft pulley position:





4. Slowly rotate crankshaft counterclockwise until original timing position (2° ATDC) is approximately 30°-50° to the left of pointer, Fig. 17. Make sure dial indicator pointer stops moving, then zero indicator. To ensure that dial indicator pointer does not deviate from zero, turn crankshaft slightly to the left and right and observe pointer.



Fig. 15 Aligning timing mark with pointer:





5. Turn crankshaft clockwise until original timing mark aligns with pointer, Fig. 15. Observe reading of dial gauge. Dial gauge should indicate .040 ±.0008 inch. If reading is as specified, injection pump timing is correct. If not, proceed to next step.
6. To adjust injection pump timing, loosen injection pump retainers and proceed as follows:
a. If dial gauge reading in Step 5 is greater than specified, rotate injection pump in reverse direction of engine rotation, until dial gauge indicates as specified in Step 5.
b. If dial gauge reading in Step 5 is less than specified, rotate injection pump in direction of engine rotation, until dial gauge indicates as specified in Step 5.
7. Tighten injection pump retaining bolts and nuts.
8. Purge air from system.



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